Endoscope riveted deflection section frame

ABSTRACT

An endoscope deflection section frame including a plurality of rings and rivets. Each ring has front ears and rear ears with rivet holes through the ears. The rivets are located in the rivet holes to thereby pivotably connect the rings to one another. Each rivet includes a head at an interior side of an inner one of the ears and an opposite end at an exterior side of an outer one of the ears. The opposite end is welded to the outer ear.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of co-pending application No.12/462,805 filed Aug. 10, 2009, which is hereby incorporated byreference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an endoscope and, more particularly, to a frameof a deflection section of an endoscope.

2. Brief Description of Prior Developments

U.S. Patent Publication No. 2005/0245789 A1 discloses an endoscopehaving a shaft frame with pivotably connected members. There is aconventional endoscope shaft riveted deflection system construction thatconsists of a number of deflection rings connected together with rivets.Each rivet has a first head. Each rivet is inserted into correspondingholes of joining rings from inside the deflection system, and then asecond head is formed from outside during the assembly.

There is another riveted deflection construction used in a Storz Flex-XFlexible Ureteroscope where the cylindrical body of each rivet is weldedto an inner ear flat surface of one of the deflection rings, and eachrivet has only one head located outside the deflection system frame. Theconventional construction having a rivet with two heads is less torqueresistant than the Storz construction; due to the clearance between therivet body and the two deflection ring holes. In the conventionalconstruction having a rivet with two heads it is difficult to controlrivet cylindrical body dimensions (of the rivet shaft section) tomaintain guaranteed clearance between the rivet head and the twodeflections rings due to the force applied to form the second rivethead. In the Storz construction, it is difficult to maintain guaranteedclearance due to welding the rivet to the inner ear flat surface of oneof the deflection rings because the welding process requires pressingthe rivet to the ring ear flat surface by force, this can deform thering which can result in a clearance problem remaining after welding.Thus, there is a desire to provide a different method of manufacture andresultant shaft frame which has better guaranteed clearance among therivet and frame rings.

SUMMARY

The following summary is merely intended to be exemplary. The summary isnot intended to limit the scope of the claimed invention.

In accordance with one aspect of the invention, an endoscope deflectionsection frame is provided including a plurality of rings and rivets.Each ring has front ears and rear ears with rivet holes through theears. The rivets are located in the rivet holes to thereby pivotablyconnect the rings to one another. Each rivet includes a head at aninterior side of an inner one of the ears and an opposite end at anexterior side of an outer one of the ears. The opposite end is welded tothe outer ear.

In accordance with one aspect of the invention, a method is providedcomprising aligning rivet holes of two endoscope deflection sectionframe members with each other; inserting a fastener into the holes; andwelding the fastener to an exterior side of one of the rings to therebypivotably attach the rings to each other.

In accordance with one aspect of the invention, a method is providedcomprising aligning rivet holes of two endoscope deflection sectionframe rings with each other; inserting a rivet into the holes, wherein ahead of the rivet is located at an interior side of a first one of therings and an opposite second end of the rivet extends to an exteriorside of a second one of the rings; inserting a mandrel into the rings,wherein the mandrel aligns the rings relative to each other and contactsthe head of the rivet to align the rivet relative to the rings,maintaining a required clearance between the rivet head and the innerring ear; and fixedly connecting the rivet to the second ring.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the invention are explainedin the following description, taken in connection with the accompanyingdrawings, wherein:

FIG. 1 is an elevational side view of an endoscope comprising featuresof the invention;

FIG. 2 is a perspective view of a portion of the frame used in theactive deflection section of the endoscope shown in FIG. 1;

FIG. 3 is a perspective view of on of the frame member rings used in theframe shown in FIG. 2;

FIG. 4 is a side elevational view of the ring shown in FIG. 3;

FIG. 5 is a cross sectional view of the ring shown in FIGS. 3-4;

FIG. 6 is a cross sectional view of the frame shown in FIG. 2 takenalong line 6-6;

FIG. 7 is a perspective view of one of the rivet used in the frame shownin FIG. 2;

FIG. 8 is an enlarged view of a portion of the frame shown in FIG. 6;

FIG. 9 is a perspective view of a mandrel being used to pre-assembly therings and rivets of the frame shown in FIG. 2 prior to welding of therivets to the rings;

FIG. 10 is cross sectional view of the assembly shown in FIG. 9;

FIG. 11 is a elevational side view of the mandrel shown in FIGS. 9-10;

FIG. 12 is a cross sectional view of the mandrel shown in FIG. 11 takenalong line 12-12; and

FIG. 13 is an elevational end view of the mandrel shown in FIGS. 11-12.

DETAILED DESCRIPTION OF EMBODIMENT

Referring to FIG. 1, there is shown a side view of an endoscope 10incorporating features of the invention. Although the invention will bedescribed with reference to the example embodiment shown in thedrawings, it should be understood that the invention can be embodied inmany alternate forms of embodiments. In addition, any suitable size,shape or type of elements or materials could be used.

The endoscope 10 is a ureteroscope. However, in alternate embodimentsthe endoscope could be any suitable type of endoscope. The endoscope 10generally comprises a handle or control 12 and a flexible orsemi-flexible shaft 14 connected to the handle 12. A deflection section(or steering section) is located at a distal end of the shaft 14. Thedeflection section, in this example embodiment, includes a passivedeflection section 16 and an active deflection section 18. A controlsystem 22 to control the active deflection section 18 extends from thehandle 12 to the active deflection section 18. The control system 22 cancomprise, for example, a pair of control wires, two wire sheaths, and anactuator 28. One end of the wires are connected to the actuator 28 andan opposite second end of the wires are connected to the distal end ofthe active deflection section 18.

In the preferred embodiment, the handle 12 has a user operated slide orlever 30. The lever 30 is connected to the actuator 28. The actuator 28is adapted to pull and release the two wires of the control system 22.When the lever 30 is moved by the user, the actuator 28 is moved. Theactuator 28 may be a drum or pulley, for example, rotatably connected tothe handle 12 to pull one wire while releasing the other. In analternate embodiment, the actuator may be any suitable type of device,such as a rocker arm adapted to pull and release the wires of thecontrol system 22. In another alternate embodiment, where the controlsystem may have two or more pairs of control wires, the handle can haveadditional actuators and corresponding controls to drive the additionalpairs of control wires to bend the deflection section in differentplane(s). In still other alternate embodiments, the handle may haveknobs with rack and pinion mechanisms or other suitable user operatedcontrols for the control system.

The shaft 14 is cantilevered from the handle 12. The flexible shaft 14and the deflection section include the control wires of the controlsystem 22, a fiber optical image bundle or video sensor electricalcable, a working channel, and a fiber optical illumination bundle orelectrical wires to illumination LEDs or lights at the objective head34. A port 60 for inserting accessory instruments (not shown) into theworking channel is located on the handle 12. The handle also has anelectrical cable 63 for connection to another device, such as a videomonitor for example. In an alternate embodiment, instead of the cable63, the endoscope could have an eyepiece. In alternate embodiments, theflexible shaft may house different systems within.

The deflection section or steering/articulation section generallycomprises a frame 26, a cover 32 and the objective head 34. The cover 32also extends over the shaft 14. However, in an alternate embodiment thedeflection section may have a different softer cover. Referring also toFIGS. 2-6, at least one portion of the frame 26 generally comprises aplurality of rings 36 and connectors 38. The connectors 38 connect therings 36 to adjacent rings. The rings 36 are preferably comprised ofstainless steel. However, the rings could be comprised of anothermaterial such as plastic or a shape memory alloy material, such as Tinelor Nitinol for example.

The rings 36 each comprise a one-piece member, but could be comprised ofmultiple members. The frame 26 shown in FIG. 2 is located at the verydistal end of the shaft 14 and the passive deflection section 16.Features of the invention could also be used at other locations of theshaft 14 or the passive section 16 as well. In this embodiment the frame26 comprises two different types of rings; short rings 36 b and longrings 36 c. The frame 26 also comprises an objective head coupler 36 afor connecting the frame 26 to the objective head, and a shaft coupler36 d for coupling the frame 26 to the frame of the shaft or the passivedeflection section. However, in alternate embodiment more or less thanfour types of rings could be provided. In addition, the rings could havedifferent shapes and sizes.

With particular reference to FIGS. 3-5, one of the short rings 36 b isshown and will be used to explain the features of the rings as anexample. Each ring 36 has a wall 40 forming a central channel 46. Thewall 40 has an exterior side 42 and an interior side 44. The wall 40forms a front side at a front end 50 of the ring, and a rear side at arear end 54 of the ring. The rings each comprise connector ears orprojections 56, 58 which extend from the front and rear ends 50, 54.Each ear has a rivet hole 48. In this embodiment, the short rings 36 band long rings 36 c have both front ears 56 and rear ears 58. Theproximal ring 36 d merely comprises front ears. The distal ring 36 amerely comprises rear ears. As seen in FIG. 6, when the ears 56, 58 of ajoining pair of rings are assembled, the front ears 56 form outer earsand the rear ears 58 form inner ears. The short and long rings includean indent feature 62 on one side which is sized and shaped forsupporting a control cable.

FIG. 7 shows one of the rivets 38 before assembly into the frame 26. Therivet 38 has a head 64 and a rivet body 66. Referring also to FIG. 8,the rivets 38 are inserted into a pair of aligned rivet holes of a pairof ears 56, 58 from two adjacent rings. More specifically, in thisembodiment the rivet is inserted from inside the deflection section(from inside the central channel 46). Thus, the head 64 is locatedagainst the interior side of the inner ear 58. The end surface 68 of therivet body 66 is located proximate the exterior surface of the outer ear56.

The rivet 38 is fixedly, stationarily attached to the outer ear 56, suchas by a weld 100 for example. In an alternate embodiment an additionalor alternative connection could be provided, such as use of additionaladhesive or a mechanical interlock for example. However, in theembodiment shown the end surface 68 is preferably welded to the exteriorsurface of the outer ear 56. The inner ear 58 is rotatably capturedbetween the head 64 of the rivet and the outer ear 56.

The proposed riveted deflection system construction can use rivets withonly one head. Each rivet can be inserted into the two joining rings'holes from inside the rings, and the rivets can be supported with amandrel inserted inside the rings. After the entire deflection system(with rings and rivets assembled) is located on the mandrel, each rivetcan be laser welded to the corresponding deflection ring outer ear.

Because each rivet is inserted from inside the rings and supported withthe mandrel, there is no need to apply any force or pressure that mightdeform the ears or rivets. The mandrel also prepositions the rings andrivets prior to welding to insure proper positioning to the designedclearances. Thus, this can result in a guaranteed or assured clearanceor tolerance (as designed) of the deflection rings and rivets assembly.Also, the proposed construction is more torque stable than theconventional rivet with two heads construction. With the invention,clearance between the rivet and only one joined ring is necessary at therivet joint.

Referring also to FIGS. 9-13, one method of manufacturing the frame 26can comprise use of a mandrel 70. The mandrel is a rod or bar, such asmade of metal for example. The mandrel 70 has grooves 72 which are sizedand shaped to receive the heads 64 of the rivets. In this embodiment themandrel 70 also has grooves 74 to accommodate the indent features 62.The front of the rivet groove 72 has a tapered shape in this embodiment.Referring particularly to FIG. 12, in one method of the invention afirst endoscope deflection frame ring is placed on a first end 80 of themandrel 70 with the inner ears 58 of the ring facing towards the firstend 80. Two rivets 38 are inserted into the rivet holes 48 of the innerears 58, wherein the head 64 of each rivet is located at an interiorside of the inner ears. A second endoscope deflection frame ring islocated on the first end 80 of the mandrel with the outer ears on theinner ears of the first ring. The rivet holes of the inner ear of thefirst ring are aligned with the rivet holes of the outer ear of thesecond ring. The first and second rings are slid on the mandrel 70 fromthe front end wherein the rivet heads 64 are pushed by cam features 82on the mandrel to move the body of each rivet into the rivet holes ofthe outer ears of the second ring. The rivets are then fixedly connectedto the second ring, such as by welding.

The rings 36 and rivets 38 are assembled on the mandrel 70 with theheads 64 of the rivets being pushed into a predetermined positionrelative to the rings 36 by the mandrel 70. The method can comprisealigning the rivet holes of two frame members with each other; insertinga rivet into the holes; and welding the rivet to an exterior side of oneof the frame members to thereby pivotably attach the frame members toeach other. The rivet is not deformed to connect the frame members,except by the welding. Inserting the fastener into the holes comprisesinserting the rivet body from an interior of the frame members to locatethe head against an interior side of one of the frame members. Weldingthe fastener comprises welding an end of the rivet body to the exteriorside of one of the rings. The mandrel aligns the frame members relativeto each other and contacts the head of the fastener to align thefastener relative to the frame members. The mandrel comprises channelsreceiving the indent features.

The method can comprise aligning rivet holes of two endoscope deflectionframe rings with each other; inserting a rivet into the holes, wherein ahead of the rivet is located at an interior side of a first one of therings and an opposite second end of the rivet extends to an exteriorside of a second one of the rings; inserting a mandrel into the rings,wherein the mandrel aligns the rings relative to each other and contactsthe head of the rivet to align the rivet relative to the rings; andfixedly connecting the rivet to the second ring. Fixedly connecting therivet to the second ring can comprise welding the rivet to the secondring. The rivet is not deformed to connect the rings, except by thewelding. The rivet holes are located in front and rear ears extendingfrom the rings. The rings comprise an indent feature on one side whichis sized and shaped for supporting a control cable, and wherein themandrel comprises channels receiving the indent features. The mandrelcomprises a groove which slidably receives the head of the rivet. Thegroove has different depths to thereby cam the rivet into the holes asthe mandrel is longitudinally slide into the rings.

It should be understood that the foregoing description is onlyillustrative of the invention. Various alternatives and modificationscan be devised by those skilled in the art without departing from theinvention. For example, features recited in the various dependent claimscould be combined with each other in any suitable combination(s). Inaddition, features from different embodiments described above could beselectively combined into a new embodiment. Accordingly, the inventionis intended to embrace all such alternatives, modifications andvariances which fall within the scope of the appended claims.

What is claimed is:
 1. A method comprising: aligning fastener holes oftwo endoscope deflection section frame members with each other on amandrel, the mandrel having a front end and a rear end; inserting afastener into the fastener holes, wherein the fastener holes are alignedby moving the two endoscope deflection section frame members on themandrel from the front end, wherein a portion of the fastener is pushedby a cam feature on the mandrel to move a body of the fastener in thefastener holes of the endoscope deflection section frame members; andwelding the fastener, from an outside direction of the frame members, toan exterior side of one of the endoscope deflection section framemembers to thereby pivotably attach the endoscope deflection sectionframe members to each other.
 2. A method as in claim 1 wherein the framemembers have a general ring shape with front and rear ears, and whereinthe holes extend through the ears.
 3. A method as in claim 1 wherein thefastener is not deformed to connect the frame members, except by thewelding.
 4. A method as in claim 1 wherein the fastener has a rivetshape with a head and a rivet body, and wherein inserting the fastenerinto the holes comprises inserting the shaft from an interior of theframe members to locate the head against an interior side of one of theframe members.
 5. A method as in claim 4 wherein welding the fastener tothe exterior side of one of the frame members comprises welding an endof the rivet body to the exterior side of one of the frame members.
 6. Amethod as in claim 4 wherein the frame members comprise an indentfeature on one side which is sized and shaped for supporting a controlcable, and wherein the mandrel comprises channels receiving the indentfeatures.